JCB 3DX, 4DX Backhoe Loader Service Manual
833 pages · Publication 9813-2050-5
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What's inside
From the manual's own table of contents: 4 sections, 582 entries. See sample pages (PDF, 476 KB)
General388 topics
- About this Publication
- Machine Nomenclature
- Machine Identification Plate
- Typical Engine Identification Number
- Rear Axle Serial Plate
- Front Axle Serial Plate
- Synchro Shuttle Gearbox Serial Plate
- Zinc Plated Fasteners and Dacromet Fasteners
- Introduction
- Bolts and Screws
- Hydraulic Connections
- O' Ring Face Seal System
- Torque Stop' Hose System
- `Quick-Connect' Pilot Hoses
- Disconnecting
- Connecting
- Numerical List
- Section B
- Section C
- Section E
- Section F
- Section H
- Section K
- Sealing and Retaining Compounds
- Colour Coding
- Hydraulic Schematic Colour Codes
- Important Information
- The Operator Manual
- Safety Warnings
- About This Manual
- Machine Model and Serial Number
- Using this Manual
- Left Side, Right Side
- Cab/Canopy
- Cross References
- Machine Description
- The JCB Backhoe Loader
- Intended Use
- Component List
- Safety Check List
- Safety - Yours and Others
- General Safety
- Operating Safety
- Maintenance Safety
- Identifying Your Machine
- Typical Product Identification Number (PIN)
- Component Identification Plates
- Transmission Identification Numbers
- Axles
- Hydraulic Pump Serial Plate
- Gearbox
- Before Entering the Cab
- Entering and Leaving the Cab
- Doors and Windows
- Opening and Closing the Door
- Opening and Closing the Side Windows
- Opening and Closing the Rear Window
- Seat Controls
- Seat Control
- For 3DX
- For 3DX XTRA, 3DX SUPER, 4DX
- Seat Belt
- Static Seat Belt
- Fasten the Seat Belt
- Release the Seat Belt
- Adjusting the Seat Belt
- Cab Layout
- From Serial Number
- Component Key From Serial Number
- Drive Controls, Switches and Instruments
- Drive Controls
- Steering Wheel
- Accelerator Pedal
- Hand Throttle Lever
- Foot Brake Pedals
- Park Brake Lever
- Transmission Lever (4-Speed Syncro Shuttle Transmission)
- Gear Lever (Syncro Shuttle Transmission)
- Transmission Dump Switch
- Switches
- Instruments
- Front Console
- Side Console
- Air-Conditioning
- General
- Air-Conditioning Controls
- Operating Levers
- Control Layouts
- Loader Controls
- Manual Controls
- Excavator Controls
- Manual Controls - JCB Diagonal (X) Pattern
- Servo Excavator Controls
- Stabiliser Controls (Non-Servo Machines)
- Lever Controls
- Stabiliser Controls (Servo Machines)
- Stabiliser indicator lights
- Auxiliary Controls
- 6-in-1 Clamshovel
- Open Bucket
- Close Bucket
- Travel Speed modes
- Economy Mode
- Power Mode
- Safety Equipment
- Boom and Slew Locks
- Boom Lock
- Slew Lock
- Beacon (if fitted)
- Before Starting the Engine
- Starting The Engine
- Starting the Engine in Cold Climate
- Warning Lights
- Preparing The Machine For Travel
- Backhoe Attachments
- Tucked In Travel Position
- Central Protruding Travel Position
- Road Travel Position
- Site Travel Position
- Getting The Machine Moving
- Operating Practices
- Stopping and Parking the Machine
- Working With The Machine
- Operating Practices and Site Safety
- Clothing and Safety Equipment
- Danger Zone
- Log Moving/Handling
- Safety Practices
- Working With The Loader
- Hydraulic Speed Control (HSC) (if fitted)
- Filling the Loader Shovel
- Loading a Truck
- Back filling
- in 1 Bucket
- Dozing/Grading
- Loading and Digging
- Grabbing
- Dozing
- Lifting and Loading Operations
- Risk Assessment
- Working With The Excavator
- Preparing to Use the Backhoe
- Kingpost Clamps
- Changing a Bucket
- Digging
- Moving the Machine while Digging Down Hill
- Sideshifting The Backhoe
- Getting the Machine Unstuck
- Operating Environment
- Operating in Low Temperatures
- Operating in High Temperatures
- Operating in Dusty or Sandy Areas
- Operating in Coastal Regions
- Operating on Wet or Soft Ground
- Refuelling the Machine
- Low Fuel Levels
- Filling the Tank
- Moving A Disabled Machine
- Towing and Retrieval
- Running Engine Procedure
- Disabled Engine Procedure
- Transporting The Machine
- Lifting A Machine
- Storage of the Machine
- Storage Area
- Prepare the Machine for Storage
- Put the Machine into Storage
- During Storage
- Take the Machine Out of Storage
- Machine Security
- Security Locks
- LiveLink
- Service Requirements
- Owner/Operator Support
- Service/Maintenance Agreements
- Initial Service and Inspection
- Health and Safety
- Lubricants
- Hygiene
- Storage
- Waste Disposal
- Handling
- First Aid - Oil
- Spillage
- Fires
- Service Schedules
- How to Use the Service Schedules
- Pre-start Cold Checks, Service Points and Fluid Levels
- Functional Test and Final Inspection
- Fluids, Lubricants and Capacities
- Coolant Mixtures
- Fuels
- Acceptable and Unacceptable Fuels
- Sulphur Content
- Effects of Fuel Contaminates
- Tools
- Toolbox
- Carrying Tools onto the Machine
- Prepare the Machine for Maintenance
- How to Make the Machine Safe (Loader Arm Lowered)
- How to Make the Machine Safe (Loader Arm Lifted)
- Installing the Loader Arm Safety Strut
- Removing the Loader Arm Safety Strut
- Cleaning the Machine
- Detergents
- Pressure Washing and Steam Cleaning
- Preparing the Machine for Cleaning
- Checking for Damage
- Check the Machine Body and Structure
- Check the Tyres
- Check the Seat and Seat Belt
- Check the Hydraulic Hoses and Fittings
- Check the Electrical Circuits
- Checking The ROPS/FOPS Structure
- Greasing
- Preparing the Machine for Greasing
- Loader Arms
- Backhoe and Quickhitch (Optional)
- Front Axle (2WD)
- Front Axle (4WD)
- Driveshafts
- Front Driveshaft
- Rear Driveshaft
- Stabilisers (Centremount Machines)
- Kingpost
- Access Panels
- Engine Cover
- Cab Machines
- Front Grille
- Side Panels
- Air Conditioning
- Cleaning the Cab Air Conditioning Filter
- Receiver Drier
- Brakes
- Park Brake
- Testing the Park Brake
- Park Brake Adjustment
- Foot Brake
- Checking the Foot Brake Fluid Level
- Electrical System
- Battery
- Battery Disconnection/Connection
- Battery Warning Indicator
- Checking the Electrolyte Level
- Jump Starting The Engine
- Fuses
- Relays
- Engine
- Oil and Filter
- Checking the Oil Level
- Changing the Oil and Filter
- Cooling System
- (Reservoir fitted Machines)
- (Non Reservoir fitted Machines)
- Front End Accessory Drive Belt
- Inspecting the Drive Belt
- Changing the Drive Belt
- Engine Air Filter
- Cleaning the Air Filter Scavenge Pipe
- Changing the Elements
- Fuel System
- Water Separator and Engine Fuel Filter
- Draining the Water Separator and Engine Fuel Filter
- Changing the Water Separator Pre-Filter
- Cleaning Water Separator Pump
- Changing the Secondary Fuel Filter
- Bleeding the System
- Mechanical Fuel Injection System
- Hydraulic System
- Releasing the Hydraulic Pressure
- Hydraulic Tank Filler Cap
- Fit the Cap
- Remove the Cap
- Checking the Fluid Level
- Changing the Filter Element
- Changing the Suction Strainer
- Transmission
- Axles (Two Wheel Steer Machines)
- Changing the Oil
- Tyres and Wheels
- Tyre Inflation
- Procedure
- Wheel Nuts
- Checking the Wheel Nut Torques
- Wear Pads
- Stabiliser Legs (Sideshift Machines Only)
- Wear Pad Adjustment
- Windscreen Washer (If fitted)
- Checking the Level
- Attachments For Your Machine
- Connecting/Disconnecting Hydraulic Hoses
- Connecting the Hydraulic Hoses
- Disconnecting the Hydraulic Hoses
- Quick Release Couplings
- Essential Do's
- Essential Don'ts
- Connecting Quick Release Couplings
- Disconnecting Quick Release Couplings
- Directly Mounted Excavator Attachments
- Installing Directly Mounted Excavator Attachments
- Shovel - Forks (If Fitted)
- Safety and Control
- Driving Up and Down Gradients
- Preparing the Forks for Use
- Preparing For Road Travel
- Preparing For Site Travel
- Adjust The Fork Spacing
- Daily Maintenance
- Tool Carrier and Forks (If Fitted)
- Preparing for Shovel Operation
- Work Platforms
- Lifting Regulations and Safe Working Loads
- Lifting (Object Handling) Regulations
- Safe Working Loads
- Loader Unit
- Static Dimensions
- 3DX, 3DX Super, 3DX Xtra
- Performance Dimensions
- Hydraulic Hose Burst Pressures
- Old Type Hose
- New Type Hose
- Technical Data
- Hammer Master Identification
- Major Components
- Basic Operation
- Start-Up
- Raising the Piston
- Piston Stroke
- Torque Settings
- External Components
- Internal Components
- Every 2-4 Hours
- Daily
- Weekly
- Initial 50-100 Hour Service
- Every 500 Hours or Yearly
- Service Procedures
- Tool Bushings
- Side Plates
- Hydraulic Pressure Testing
- Lower Tool Bushing and Tools
- Checking For Excessive Wear (Monthly)
- Lower Tool Bushing
- Removal
- Swivel Couplings
- Removal and Dismantling
- Assembly and Replacement
- Accumulators
- Removal and Replacement
- Dismantling and Assembly
- Charging
- Pressure Adjusting Valve
- Adjustment
- Tie Rods
- Inspection
- Valve Body
- Cylinder
- Front Head
- Charging Procedure
- Glazing
- Direct Glazing
- Slide Hammer Kit
- Fitting Procedure
- Rivet Nuts
- Welding
- Removal, Front Mountings
- Removal, Rear Mountings
- Replacement
- Operation Overview
- System Operation
- System Controls
- Safety Procedures
- Service Checks
- Off-Season Operation
- Fault Finding
- Fault Indications
- System Diagnosis using Test Gauges
- Test Procedures
- Leak Testing
- Tightening Leaking Hoses
- Refrigerant Charge Level
- Refrigerant
- R134a Refrigerant
- PAG Type Refrigerant Oil
- Refrigerant Charging and Discharging
- Cleaning
- Fuel Level Sender
- Fluid Level Sight Glass
Section B - Body and Framework73 topics
- Sideshift Machines
- Boom
- Dipper
- Clearances
- Clearance on Backhoe, Loader and Mainframe
- Kingpost and carriage
- Sideshift Carriage
- Using a Multimeter
- Measuring DC Voltage
- Measuring Resistance
- Measuring Continuity
- Measuring Frequency
- Testing a Diode or a Diode Wire
- Maintenance
- Testing
- Specific Gravity Testing
- Alternator
- General Description
- Service Precautions
- Charging Circuit Test
- Alternator Charging Test
- Starter Motor
- Starting Circuit Test
- Electrical Circuit - 3DX
- Electrical Circuit - 3DX Xtra, 3DX Super and 4DX
- Harness Data - 3DX
- Harness Data - 3DX Xtra, 3DX Super and 4DX
- Fuses (3DX Standard without Livelink)
- Fuses (3DX Xtra, Super and 4DX with Livelink)
- Relays (3DX Standard)
- Stop)
- VIN Flashing
- Diagnostics Process
- Steering column
- Dismantle and Assemble
- Loader Valve Controls
- Excavator Valve Controls
- Auxiliary Foot pedal Control
- Loader Control Knob
- Removal and Installation
- Installation
- Machine Hydraulics
- Hydraulic Pump Flow and System Pressure
- Gear Pump
- Loader Valve Block
- Main Relief Valve
- Excavator Valve Block
- Backhoe
- Attachments
- Introduction to Hydraulic Schematic Symbols
- General (Basic and Functional Symbols)
- Control Valves
- Example of Schematic Circuit
- Component Location and Neutral Circuit Descriptions
- Gear Pump - Double Pump
- 3DX BSIII with JCB Ecomax Engine
- 3DX Xtra, 3DX Super and 4DX
- Gear Pump - Operation
- Single Pump - Operation
- Double Pump
- Machines from Serial no. 964125 (High Pressure)
- Unloader Valve
- Main Relief Valve (MRV) - Operation
- Main Relief Valve (MRV)
- Loader Valve - Neutral Circuits
- Neutral Circuit
- Unloader Operation (If fitted)
- Hydraulic Speed Control (HSC)
- Load Hold Check Valves
- Arms Lower Operation
- Float
- Auxiliary Relief Valve
- Main Relief Valve (MRV) Operation
Section E - Hydraulics82 topics
- Excavator Valve
- One Way Restrictor
- Excavator Valve - Slew Operation
- Slew Ram End Damping
- Slew A.R.V. and Anti-Cavitation Operation
- Excavator Valve - A.R.V. Operation
- Auxiliary Relief Valve Operation
- Auxiliary Relief Valve - Anti-Cavitation
- ation
- Hydraclamp (Sideshift Machines)
- Hydraulic Contamination
- Hydraulic Fluid Quality
- Effects of Contamination
- Cleaning Operation
- Contaminant Standards
- Filters
- Hydraulic Pump
- Flow and Pressure Testing
- Loader Valve (Unloader valve)
- Shovel Ram Rod Side A.R.V. Pressure Testing
- Dismantling, Inspection and Assemble
- Loader Valve - Pressure Testing
- Main Relief Valve (M.R.V.)
- Auxiliary Relief Valves - Using Hand Pump
- Excavator Valve - Pressure Testing
- Ram Creep Tests - All Services
- Valve Block Spool Seals
- Seal Fitting - 3DX
- Seal Fitting - 3DX ECO
- Hydraclamp Valve - Dismantling and Assembly
- Hydraulic Adaptors (Positional Type)
- Standard Spool
- Float Spool
- Electric Detent Spool
- Component Identification
- 3DX Xtra and 4DX
- 3DX Super
- Open End Kit
- Valve Block
- Auxiliary Relief Valves (ARV's)
- Hydraclamp Valve (Sideshift Machines)
- Hoses and Pipes (Sideshift Valve)
- Hoses and Pipes (Centremount Valve)
- Description
- For 3DX Xtra, 3DX Super (Base and AC)
- For 3DX Xtra and 3DX Super (Servo)
- Sideshift Machine
- Description and Operation
- Operation
- Precautions During Use
- Caution During Use
- Maintenance, Inspection Points
- Loader Shovel Ram
- Loader Lift Ram
- Bucket Crowd Ram
- Dipper Ram
- Boom Ram
- Slew Ram
- Stabiliser Ram (Sideshift)
- Priority Valve
- JCB Ram Sealing Procedure
- Assembly and Disassembly
- Typical Ram
- Front Axle
- Principal of Operation
- Torque Converter
- Synchromesh
- Synchro Shuttle Gearbox Synchromesh (Blocking Pin Type)
- Synchromesh - Operation
- Dismantle, Inspection and Assembly
- Torque Convertor
- Removeal
- Service Procedure
- Torque Converter Stall Test
- Removing and Replacing
- Torque Setting
- Swivel and Drive shaft
- Selecting the spacer
- Pinion Depth Setting
- Crown Wheel and Pinion Meshing
- Hub End Torque
- Synchro Shuttle Gearbox
Section G - Brakes13 topics
- Overview
- Master Cylinder
- Compensating Master Cylinder
- Pedals Locked - Normal Operation
- Pedals Locked - Compensating Operation
- Pedals Unlocked - Normal Operation
- Without Compensatory
- With compensatory
- Service Brakes
- Brake Light Switch
- Parking Brake - Adjustment
- Bleeding
- Park Brake Caliper
Section H - Steering22 topics
- Wheel Steer Machines
- Steer System
- Operation 1 - Neutral
- Right Turn
- Priority Valve - Neutral
- Load Sensing Dynamic Signal Non Load Reaction
- Specification Data
- VLC Priority Valve (BOPV)
- Pressure Test
- Priority Valve - Standby Pressure Testing
- Priority Valve - Cleaning
- Rams
- Hydraulic Steer Unit (Eaton)
- Exploded VIew
- Hydraulic Steer Unit (VSP)
- Steering wheel difficult to turn K Table 13. ( T H-48)
- diagrams (near the beginning of the Hydraulics Section)
- information at the beginning of this manual
- component
- hydraulic fluid. Drain and replace necessary
- to the hydraulics
- elsewhere in the circuit
Inside this manual
Real pages from this service manual (833 pages). Open the sample pages (PDF, 475 KB)
- Specifications, page 264: Specifications
- Diagram, page 468: Section E - Hydraulics
- Troubleshooting, page 780: Section G - Brakes
- Color page, page 627: Hydraulic Rams
- Color page, page 705: Front Axle
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 833 pages
Quantity one is the manual described above.
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Other editions and similar models
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